Spray Painting and Powder Coating N

8/10/2019 Spray Painting and Powder Coating N

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DRAFTCode of Practice

SPRAY PAINTING AND

POWDER COATING


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Table of Contents

FOREWORD .............................................................................................................................. 3

SCOPE AND APPLICATION...................................................................................................... 3

1.

INTRODUCTION ................................................................................................................. 4

1.1 What are spray painting and powder coating? ............................................................... 41.2 Who has health and safety duties in relation to spray painting and powder coating? ..... 41.3 What is involved in managing the risks of spray painting and powder coating? ............. 5

2.

HOW TO IDENTIFY THE HAZARDS .................................................................................. 6

2.1 Identifying hazardous chemicals.................................................................................... 7

3. HOW TO ASSESS THE RISKS ........................................................................................ 103.1 Assessing the risks of hazardous chemicals................................................................ 10

4. HOW TO CONTROL THE RISKS OF SPRAY PAINTING ................................................ 124.1

The hierarchy of risk control ........................................................................................ 12

4.2 Spray painting in spray booths .................................................................................... 124.3 Ventilation systems ..................................................................................................... 15

4.4

Spray painting outside a spray booth .......................................................................... 16

4.5 Maintenance................................................................................................................ 164.6

Personal protective equipment .................................................................................... 17

4.7 Information, training, instruction and supervision ......................................................... 19

5. HOW TO CONTROL THE RISKS OF POWDER COATING ............................................. 215.1 Hazardous chemicals .................................................................................................. 215.2 Controlling exposure ................................................................................................... 215.3 Electrical safety ........................................................................................................... 23


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FOREWORD

This Code of Practice for managing the risks associated with spray painting and powder coating isan approved code of practice under section 274 of the Work Health and Safety Act (the WHS Act).

An approved code of practice is a practical guide to achieving the standards of health, safety andwelfare required under the WHS Actand the Work Health and Safety Regulations (the WHSRegulations).

A code of practice applies to anyone who has a duty of care in the circumstances described in thecode. In most cases, following an approved code of practice would achieve compliance with thehealth and safety duties in the WHS Act, in relation to the subject matter of the code. Like

regulations, codes of practice deal with particular issues and do not cover all hazards or riskswhich may arise. The health and safety duties require duty holders to consider all risks associatedwith work, not only those for which regulations and codes of practice exist.

Codes of practice are admissible in court proceedings under the WHS Act and Regulations. Courtsmay regard a code of practice as evidence of what is known about a hazard, risk or control andmay rely on the code in determining what is reasonably practicable in the circumstances to whichthe code relates.

Compliance with the WHS Act and Regulations may be achieved by following another method,such as a technical or an industry standard, if it provides an equivalent or higher standard of workhealth and safety than the code.

An inspector may refer to an approved code of practice when issuing an improvement orprohibition notice.

This Code of Practice has been developed by Safe Work Australia as a model code of practiceunder the Council of Australian Governments Inter-Governmental Agreement for Regulatory and

Operational Reform in Occupational Health and Safety for adoption by the Commonwealth state


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1. INTRODUCTION

1.1 What are spray painting and powder coating?

Spray painting, including electrostatic spray painting, is a process by which liquid paint is appliedunder pressure to an object. Spray painting may be carried out by hand or automatically. Thereare several methods used to atomise the paint for spraying:

a) Using a conventional air compressor air is driven across the mouth of a small outlet underpressure to draw liquid paint out of the container and produce an air-paint mist from thenozzle of the spray-gun.

b) Airless spray painting the paint container is pressurised pushing the paint to the nozzlewhere it is atomised by the spray gun.

c) Electrostatic spray painting an electric pump drives the electrostatically charged liquidpaint out of the nozzle which is then applied to the object which is earthed.

Powder coating is a process by which electrostatically charged powder is applied onto an earthedobject.

Spray painting and powder coating are carried out in a variety of industries. For example, itemsthat are commonly spray painted include motor vehicles, buildings, furniture, white goods, boats,ships, aircraft and machinery.

1.2 Who has health and safety duties in relation to spray painting and powdercoating?

A person conducting a business or undertaking has the primary duty under the WHS Act toensure, so far as is reasonably practicable, that workers and other persons are not exposed to

health and safety risks arising from the business or undertaking


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1.3 What is involved in managing the risks of spray painting and powder coating?

Identifying all reasonably foreseeable hazards and understanding the level of risk associated withspray painting and powder coating work will help you make the right decisions about what to do toeliminate or minimise the risks. This process is known as risk management and involves thefollowing steps:

identifying hazards

if necessary, assessing the risks associated with the hazards

implementing risk control measures, and

reviewing the effectiveness of control measures.

Guidance on the general risk management process is available in the Code of Practice: How toManage Work Health and Safety Risks.

Consulting your workers

Consultation involves sharing of information, giving workers a reasonable opportunity to expressviews and taking those views into account before making decisions on health and safety matters.

The WHS Act requires that you consult, so far as is reasonably practicable, with workers who carryout work for you who are (or are likely to be) directly affected by a work health and safety matter.

If the workers are represented by a health and safety representative, the consultation must involvethat representative.

Consultation with workers and their health and safety representatives is required at each step ofthe risk management process. By drawing on the experience, knowledge and ideas of yourworkers you are more likely to identify all hazards and choose effective control measures.

Consulting, co-operating and co-ordinating activities with other duty holders

The WHS Act requires that you consult, co-operate and co-ordinate activities with all other personsh h k h lth f t d t i l ti t th tt f i bl


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2. HOW TO IDENTIFY THE HAZARDS

Identifying hazards involves finding all of the things and situations that could potentially causeharm to people and workers who carry out spray painting and powder coating. Hazards may arisefrom:

the work environment

the plant and equipment used

the types, quantities and properties of substances used, and

the work tasks and how they are performed.

Table 1below lists the common hazards associated with spray painting and powder coating.

Table 1 Examples of common spray painting and powder coating hazards

Hazard Potential harm Examples

Hazardouschemicals

Can harm health of workers, for examplefrom dermatitis, respiratory illnesses andcancers. Some hazardous chemicals arefire and explosion risks

Products containingisocyanates, paints, solvents,

adhesives, resins, rustremovers, rust converters,lacquers and degreasers

Fire and explosionSerious burns and death, exposure toprojectiles and damage to property

Flammable paints and solventsmay come into contact with anignition source.Combustible dusts can be usedin powder coating.

Confined spaces

Exposure to hazardous chemicals, unsafe

oxygen levels potential for fire explosionSpraying inside the cavity ofvehicles ships aircraft or tanks


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reading product labels, safety data sheets and manufacturers instruction manuals

talking to manufacturers, suppliers, industry associations and health and safety specialists,

and reviewing incident reports.

2.1 Identifying hazardous chemicals

Exposure to hazardous chemicals is a significant risk in spray painting and powder coatingactivities, including during preparation (preparing surfaces, tinting, mixing and pouring paints),storage, clean-up and disposal. The hazardous chemicals include paints, solvents, powders,lacquers, paint strippers, adhesives, surface preparation products, rust converters and rust

removers.

Health effects from exposure to chemicals can become apparent after a short period and includeheadaches, nausea or vomiting, dizziness, burns to the skin or eyes and irritation to the nose,throat and lungs. Serious long term health effects include asthma, dermatitis, kidney or liverdamage, cancer and damage to the reproductive system and central nervous system.

Hazardous chemicals can enter the body by inhalation into the lungs, absorption through the skin

and eyes and through swallowing including accidently ingesting small amounts.

A person conducting a business or undertaking must manage risks to health and safetyassociated with using, handling, generating or storing a hazardous chemical at theworkplace. In doing so, consideration must be given to the hazardous properties of thechemical, the potential for chemical or physical reactions, the nature of the work to becarried out with the chemical and any structure, plant or system of work that is used orcould interact with the use, handling, generation or storage of the hazardous chemical.

The following chemicals must not be used, handled or stored for spray painting:

o arsenic


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Table 2 Examples of hazard information on labels and safety data sheets

Label element Examples

Signal words Danger

Warning

Hazard statements May cause cancer

Fatal if inhaled

Flammable liquid and vapour

Causes severe skin burns and eye damage

May cause respiratory irritationPictograms

Precautionary statements Use explosion proof electrical equipment

Do not breathe vapours

Do not get in eyes, on skin or clothing

Use only outdoors or in a well ventilated area

If on skin: Wash with plenty of soap and water

Y h ld l id tif d t f t d b di d f ti F


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The WHS Regulations contain specific requirements for working with lead, including theidentification of lead risk work and removing a worker from lead risk work in certain circumstances.

Hazardous chemical registers

You must maintain a register of the hazardous chemicals used, handled or stored in spray painting.The purpose of this register is to provide a source of information for both you, your workers andanyone else affected by a hazardous chemical, and to assist in the management of substancesused or generated in spray painting processes. The register must list all the hazardous chemicalsat your workplace and their current safety data sheet. The register must be readily accessible toanyone who is likely to be affected by a chemical and workers who are involved in using, handlingor storing a chemical in the register.

The register must contain a list of the hazardous chemicals found in paints, coatings, solvents andthinners, fillers, strippers and cleaning products.

Exposure standards

Exposure standards refer to airborne concentrations of a substance (whether as a fume, mist, dust,vapour or gas) under which it is considered nearly all workers can be repeatedly exposed five daysa week for eight hours a day throughout their working life, without adverse health effects.

Exposure standards are listed in the Workplace Exposure Standards for Airborne Contaminants.These do not represent levels at which every worker can be guaranteed protection, therefore youshould ensure that the level of exposure to any hazardous chemical is kept as low as is reasonably

ti bl Thi i l d t h d h i l th t d t h d l d

A person conducting a business or undertaking must ensure that no person at theworkplace is exposed to a substance or mixture in an airborne concentration more than theexposure standard for the substance or mixture.


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3. HOW TO ASSESS THE RISKS

Hazards have the potential to cause different types and severities of harm, ranging from minordiscomfort to a serious injury or death. For example, exposure to spray painting and powdercoating chemicals can adversely affect a workers health in ways ranging from minor illness (forexample, headaches) to major illness (for example, asthma).

In addition, many spray paints contain flammable substances. Spray painting vapours and mistscan spread rapidly, particularly in an enclosed space, and create a potentially explosiveatmosphere. If the mist or vapour is ignited, for example by a cigarette or spark, it could result in an

explosion that could destroy the building and kill or injure anyone nearby. Each of the outcomesinvolves a different type of harm with a range of severities, and each has a different likelihood ofoccurrence.

A risk assessment involves considering what could happen if someone is exposed to a hazard andthe likelihood of it happening. A risk assessment can help you determine:

how severe a risk is

whether any existing control measures are effective

what action you should take to control the risk, and

how urgently the action needs to be taken.

The following questions may help to assess the risk:

How many persons are exposed to the hazard?

How often, and for how long, will exposure to the hazard occur?

How do workers interact with the hazard (for example, being exposed to hazardouschemicals by breathing it in or skin contact)

Is there evidence of contamination (for example dust or fumes visible in the air, chemicalodours, spills, splashes)?

Wh h di i d hi h h k i i d (f l i fi d


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Low riskchemicals

Hazardous chemicals that are low risk include any other substances not already assessedas high or medium.

The level of risk depends not only on the toxicity or flammability of the hazardous chemical but alsoon the nature of exposure, including frequency of use, quantities used, effectiveness of existingcontrols and the type of process. For example, some spray painting processes may be moresuitable than others when attempting to minimise the exposure of a hazardous chemical or the riskof fire (see Table 4 below).

Table 4 Characteristics of spray painting and powder coating processes

Process Characteristics

Conventional compressed air (lowpressure) spray painting

extensive overspray of potentially hazardous chemicals

bounce of potentially hazardous chemicals in cavities and atcorners (rebound)

Airless (high pressure) spray painting

risk of injection injury and static electricity that could cause aspark

less overspray, bounce and aerosol than conventional air

spraying relatively high viscosity paints can be used (less solvent is

needed in the paint)

higher capacity (flow rate) and faster application.

Air assisted airless spray painting risk of injection injury

less aerosol and overspray than conventional air spraying.

P d C ti

high risk chemicals are used in surface preparation, includingchromates and hydrofluoric acid

i k f t i b ti l t d t ti l t i it


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4. HOW TO CONTROL THE RISKS OF SPRAY PAINTING

4.1 The hierarchy of risk controlThe ways of controlling risks are ranked from the highest level of protection and reliability to thelowest. This ranking is known as the hierarchy of risk control. Duty holders must work through thishierarchy when managing risks under the WHS Regulations.

Eliminate the risk

Removing the hazard is the most effective control measure, for example remove all ignitionsources to eliminate the risk of fire or stop using a hazardous chemical to eliminate exposure.

Minimise the risk

If it is not reasonably practicable to eliminate the risks, you must minimise the risk associated withspray painting and powder coating work so far as is reasonably practicable by choosing one ormore of the following measures:

Substitution Replacing a hazardous process or material with one that is less hazardouswill minimise the risk. For example,

o use a water-based paint instead of an organic solvent based coating

o use a brush or roller instead of a spray guno use a triglycidyl isocyanurate-free (TGIC) powder coating instead of one containing

TGIC, ando use high volume low pressure (HVLP) spraying rather than airless spraying.

Isolation Removing the worker from the hazard by totally isolating the spray painting in aspray booth using a fully automated process.

Engineering Use control measures such as ventilation systems to reduce exposure tovapours and aerosols.

If th i i i i k it t b i i i d f i bl ti bl b


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Types of spray booths include:

Downdraft spray booths, where air enters the booth from the ceiling through a filtering

system, and moves downwards vertically. Heavy and large objects, like cars, which are noteasy to handle are often painted in the down draft spray painting booths.

Semi downdraft booths, where fresh air enters the booth from outside the building, isducted through the roof intake filters, and is drawn towards the rear exhaust wall of thebooth where it is exhausted through filters.

Open-faced spray boothsgenerally have two walls, roof with air extraction, a filtered rearwall and an open front.

Tunnel or production spray boothsfor mass produced items requiring a continuous painting

application process. These booths are usually down draught or cross draught and haveopen ends.

Spray booths should:

be designed, constructed and installed to comply withAS/NZS 4114.1 Spray paintingbooths

be fitted with an exhaust capture system and a ventilation system that includes a filter forremoving airborne contaminants

have ventilation systems capable of producing a minimum air movement of:

o 0.3 m/s for a full downdraft bootho 0.4 m/s for electrostatic sprayingo 0.5 m/s for any other booth.

be inspected at regular intervals and maintained according to manufacturers specifications

have a sign indicating the time people should allow for chemicals to clear before enteringthe spray booth.

Spray booth ventilation control systems should operate a pre-purge cycle to remove any residuecontaminants and also operate a minimum of a 5 minute post-purge period following spraying.


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Figure 3: The Spraying with ashort nozzle may causeoverspray of the operator.

Figure 4: Spraying with a long nozzleavoids overspray of the operator.


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Even with a ventilation system, there is still potential for flammable mists and vapours toaccumulate inside the spray booth, which can increase the risk of fire and explosion. You shouldensure that the equipment that will be used in a spray booth and spray painting ventilation systemscomply withAS 1482 Electrical equipment for explosive atmospheres protection by ventilationandAS/NZS 60079.25:2004 Electrical apparatus for explosive gas atmospheres - Intrinsically safe

t

Figure 7: The operator is exposed tooverspray and stretching and reaching

can cause discomfort and injury.

Figure 8: The use of a gantry or liftavoids overspray on to the operator and

avoids them having to stretch andreach.


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4.4 Spray painting outs ide a spray booth

Where it is not practicable to do the spray painting in a booth and it is carried out in a building or

structure other than a confined space, the building or structure should be of open construction or amechanical exhaust system should be used to prevent the build-up of flammable or toxic fumes.

A spray painting exclusion zone should be designated around the area where the spray painting iscarried out. In general, the exclusion zone should have at least six metres horizontal and twometres vertical clearance above and below the place where the paint is being applied. However, indeciding where to establish an exclusion zone and how big it should be, you should consider:

the nature of the substances being sprayed

the type of process being used the workplace environment, including wind speed, temperature and humidity, and

the location of other people.

Greater vertical clearance may be needed when spray painting in stairwells and other areas whichallow vertical movement of vapours.

Once a spray paint exclusion zone is established, a number of procedures can be used to controlrisks, including:

physical barriers and warning signs to prevent unprotected persons from entering theexclusion zone

shrouding the area where spraying is to occur to prevent spray drift in walkways, publicareas and air conditioning intake vents

removing hazardous chemicals that are not needed for spray painting work, to reduceunnecessary exposure and fire or explosion risks

removing stored wastes, like solvent-soaked rags and waste paint, to control fire orexplosion risks

removing electrical and ignition sources from within the exclusion zone to control fire and


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regular servicing of all equipment and plant

procedures for reporting and repairing faulty equipment, and

records of servicing, maintenance, repair and testing of plant and equipment should be keptfor future reference.

When undertaking maintenance of equipment, ensure that:

spraying equipment is regularly cleaned and maintained in accordance with themanufacturers instructions

spray guns are tested in a safe manner

spray booths are cleaned regularly. Cleaning of spray booths is made easier by covering

exposed surfaces with non-flammable plastic film, which can be easily removed forcleaning or washing. The use of absorbent material, for example paper, cardboards,wooden platforms, should be avoided.

the air filter medium is cleaned according to the manufacturers instructions. Frequentcleaning or replacement of the filter medium is required to prevent deposits blocking airflow. Never spray paint in the spray booth without an air filter medium, and

pressurised paint pots and pressurised spray guns are cleaned in accordance withmanufacturers instructions. Pressure from the gun and the paint pot should be released

prior to cleaning. The gun should never be cleaned by covering the nozzle with a cloth orother material held in the hand, as this method of cleaning can result in paint injectioninjuries when used with airless spray guns.

4.6 Personal protective equipment

In most cases PPE must be worn by workers when spray painting and powder coating tosupplement higher level controls such as ventilation.

If l t ti i t (PPE) i t b d t th k l th d ti th


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PPE type Hazards Recommendation

Acoustics - Hearing protectors.

Gloves and clothing Exposure tohazardouschemicals

Gloves and clothing should protect exposed skin. Gloves and clothing should comply with AS/NZS

2161 (series) - Occupational protective glovesandAS/NZS ISO 13994:2006 : Clothing for protectionagainst chemicals - Determination of the resistanceof protective clothing materials to penetration byliquids under pressure.

Foot protection(e.g. boots and shoes)

Trips, slips andexposure to

hazardouschemicals

Foot protection should be non-slip and be heat andfire resistant.

Protection should comply with AS/NZS 2210(series) - Occupational protective footwearandAS/NZS 2210.1-1994 - Occupational protectivefootwear - Guide to selection, care and use.

Respiratory protectivedevices(e.g. dust masks, half facerespirators and air suppliedrespirators)

Dusts, aerosols,vapours, gases andoxygen depletedatmospheres

Workers carrying out spray painting with two partepoxy or polyurethane paint, or some catalyticacrylic paints should be provided with either a fullface piece supplied air respirator or half face piecesupplied air respirator.

Respirators should be fitted for each personindividually. The tightness of all connections and thecondition of the face piece, headbands and valvesshould be checked before each use. Air suppliedrespirators may be required in some situations, forexample, confined spaces. Select air suppliedrespirators that generate less noise so the workercan hear warning signals and will not become easilytangled or caught on other objects.

R i t h ld l l fit th t id


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The respiratory protective equipment required will depend on the toxicity of the paint and theconditions under which the paints are applied. When selecting respirators, the following points

should be considered: exposure standards for the various paint components. Exposure standards have not been

established for some of the hazardous components of these paints, for example, curingagents

the information provided in the manufacturers safety data sheets

ventilation in the area where the paint is to be applied

the level and duration of exposure, and

the protection factor of the respirator.

No person should use two part epoxy paint or two part catalysed acrylic paint without firstconsidering the information provided in the safety data sheets for these paints.

When spraying two part epoxy paint or two part catalysed acrylic paint the sprayer should wear:

respiratory protection that maintains exposures below the exposure standard. Where thereis no exposure standard, exposures should be kept as low as reasonably achievable. Halfface respirators with combined particulate/organic vapour cartridges may be used in wellventilated areas. Higher protection factors (for example, full face or powered air purifyingrespirators) will be required where ventilation is not adequate. When spraying in poorlyventilated or enclosed areas, particular care should be taken to ensure that appropriatepersonal protective equipment is worn in accordance with the recommendations containedin the manufacturers safety data sheet, and

full length overalls, appropriate chemically resistant gloves and eye protection.

Organic solvent and water based paint

When organic solvent or water based paints are being sprayed and the exposure standard is likelyto be exceeded, the sprayer should wear:

i t ith bi d / ti l t filt Wh i i i d t i


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using and maintaining personal protective equipment

the requirements for labelling chemicals, the information that each part of the label

provides and why the information is provided information about health monitoring

first aid and emergency procedures, including incident reporting.

Training should be practical and where relevant include hands-on sessions, for example, correctlysetting up a spray zone or practising emergency procedures. Training, instruction and informationshould be provided in a form that can be understood by all workers.


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5. HOW TO CONTROL THE RISKS OF POWDER COATING

Powder coating is a process by which powder is applied onto a charged object. It is theelectrostatic charge on the powder and the object that will make the powder stick onto the surfaceof the object being sprayed.

It is through powder coating process that workers are more likely to encounter hazards and risksassociated with the use of electrical equipment, for example, static electricity and potential ignitionsources. Workers are also more likely to be exposed to triglycidyl isocyanurate and experienceadverse health effects.

5.1 Hazardous chemicalsTriglycidylisocyanurate (TGIC)

TGIC is classified as a hazardous chemical and is commonly used in powder coating processes. Itis:

a skin sensitiser

toxic by ingestion and inhalation

genotoxic, and

capable of causing serious eye damage.

You should check safety data sheets and labels to determine if the product you are using containsTGIC.

Powder coatings containing TGIC are applied by electrostatic process. Workers who may comeinto direct contact with TGIC powder coatings include persons:

filling hoppers

manually spraying powder coatings, including touch-up spraying

l i i d


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Engineering controls

The most effective engineering controls for reducing worker exposure are booths, local exhaust

ventilation and automation of the spray process. In particular: application of powder coatings should be performed in a booth (seeAS 3754-1990 - Safe

application of powder coatings by electrostatic spraying) where practicable

local exhaust ventilation should be used when spraying, during filling of hoppers whenreclaiming powder and during clean-up

using automatic spray guns, feed lines and feed equipment

to prevent unnecessary powder build-up inside spray booths, minimise spray gun airpressure to prevent overspray

the power supply and powder coating feed lines should be interlocked with the airextraction system so that if a fault develops in the ventilation system, the powder coatingand power supplies are cut off

opening powder coating packages, loading of hoppers and reclaiming powder areoperations which should be contained to prevent or minimise the generation of dusts

the layout of the work station and the size of the hopper opening should be such thatgeneration of dust is minimised when filling the hopper, and

the following should be considered regarding the use of hoppers:

o use spray systems where the container in which the TGIC is supplied can be usedas the hopper, thereby avoiding the need to transfer powder

o large hoppers can be used to avoid frequent refilling of smaller units, ando powder coatings that are supplied in drums allow for the powder to be transferred

mechanically rather than manually.

Administrat ive contro ls

Administrative controls should be used to support other measures in order to reduce worker

Ad i i i l i l d


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regularly checking that plant and equipment are being cleaned and maintained, includingventilation and spray equipment and filters, and

proper induction training and general training of workers.

5.3 Electrical safety

Powder coating processes brings with it electrical hazards and additional requirements for safework practices are required. Electrostatic spray-guns have electrically charged nozzles whichtransfer the electric charge to droplets of paint which are then attracted to the edges and back ofthe work piece, an effect known as the wrap-around effect. In some automatic painting processesthe objects to be painted are charged. Direct current sources are used and hand guns may be

designed with safe nozzles carrying a very low current at high voltage. Automatic guns carry muchhigher currents which are potentially lethal.

All equipment, including spray guns and booths should be earthed. All hooks used to suspendobjects to be sprayed should be cleaned prior to re-use in order to maintain effective metal contact.Earthing of equipment, objects being coated and personnel ensures maximum coating efficiency,reduces free dust and prevents build-up of static charges capable of causing ignition.

In an electrostatic spraying system, atomised droplets are charged to a high voltage (at least 60

kilovolt) so that they are attracted to an earthed work piece. Although this process reduces the riskof overspray and ricochet, there is a risk of electric spark ignition both at the spray gun nozzle andat the wetted surface of the work piece.

All equipment and metal surfaces within three metres of the charged head of the spray gun shouldbe earthed. This includes:

the floor of the exclusion zone this should be of a material that is electrically conducting tothe earthing of the spray gun (clean any overspray from the floor to avoid build-up of aninsulating layer)

h l h i d h dl f h h l h h dl f h d


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6. MONITORING AND REVIEWING CONTROL MEASURES

The control measures that are put in place to protect health and safety should be regularlyreviewed to make sure they work as planned. This may involve, for example, air monitoring tomeasure the amount of solvents in the workers breathing zone where spray booths are not beingused, or reviewing paint mist clearance times following the introduction of spray booths.

If the control is not working effectively the control method must be reconsidered and furtherremedial action taken.

6.1 Air monitor ing

Air monitoring is the sampling of workplace atmospheres to obtain an estimate of workers potentialinhalation exposure to hazardous chemicals. Air monitoring can be used:

to indicate whether the exposure standards are being exceeded or approached

when there is uncertainty about the level of exposure

to help with the risk assessment process, and

to test the effectiveness of the control measures.

Air monitoring is not normally required in spray painting or powder coating if workers wearappropriate respiratory protective equipment. However, it may be required in limited cases where:

the operator wears no respiratory protective equipment and the process is controlled byother means such as an open spray painting booth, or

the monitoring is necessary to establish the use or the required protection factor ofrespiratory protective equipment.

A person conducting a business or undertaking must ensure that atmospheric monitoring is

f f


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establishing whether an identifiable disease or health effect known to be linked to exposureto dust or other chemicals is present, and

determining levels of toxic substances in the body so informed decisions can be madeabout the effectiveness of controls and whether any further action needs to be taken (forexample, a reduction in or cessation of exposure).

While air monitoring is the primary workplace monitoring technique, if hazardous chemicals mayhave been absorbed through the skin, ingested or inhaled, biological monitoring techniques shouldalso be used. For example, biological monitoring for toluene in the blood measures the amount oftoluene that workers have in their bodies as a result of spray painting exposures, by analysing asmall sample of their blood.

Biological monitoring has the specific advantage of being able to take into account individualresponses to particular hazardous chemicals. Individual responses are influenced by factorsincluding size, fitness, personal hygiene, work practices, smoking and nutritional status.

Health monitoring should not be used as an alternative to proper implementation and maintenanceof control measures designed to prevent exposure. For more information on health monitoringtechniques required (for example, x-ray and respiratory function tests), see Schedule 14 of theWHS Regulations.

Health monitoring report

A report must be obtained from the medical practitioner who supervised the health monitoring assoon as possible after the monitoring is carried out and a copy provided to the worker as soon asreasonably practicable. The report must include:

any test results that indicate the worker has been exposed to a hazardous chemical

any advice indicating an injury or illness as a result of carrying out the work that triggeredthe health monitoring

any recommendations about the remedial measures the person conducting the business or


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if air monitoring indicates that the airborne concentration of a hazardous chemical at theworkplace exceeds the relevant exposure standard, and

at least once every 5 years.

You can use the same methods as in the initial hazard identification step to check controls. Consultyour workers and their health and safety representatives and consider the following questions:

Are the control measures working effectively in both their design and operation?

Have the control measures introduced new problems?

Have all hazards been identified?

Have new work methods, new equipment or chemicals made the job safer?

Are safety procedures being followed?

Has instruction and training provided to workers on how to work safely been successful?

Are workers actively involved in identifying hazards and possible control measures? Arethey openly raising health and safety concerns and reporting problems promptly?

Are the frequency and severity of health and safety incidents reducing over time?

If new legislation or new information becomes available, does it indicate current controlsmay no longer be the most effective?

If problems are found, go back through the risk management steps, review your information and

make further decisions about risk control.


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7. OTHER HAZARDS AND RISK CONTROL

7.1 Fire and explosion

The use of flammable materials in spray painting, for example, organic solvents, increases the riskof fire and explosion because of the amount of solvent vapour in the air.

Powder coatings are combustible dusts and the accumulation of powders could lead to a majordust explosion. Consider surfaces that are out of sight where dust may accumulate (for example,suspended ceiling) and ensure such areas are regularly inspected and cleaned, or sealed off toprevent dust accumulation.

Sources of ignition include:

open flames, including matches, lighters, cigarettes, cutting torches and welding

hot surfaces including engines, motors and light bulbs

chemical reactions, mixing hazardous chemicals can generate heat or static and create anignition source

sparks from electric equipment, portable electric tools, power points, radios, mobile phonesor from the discharge of static electricity from poorly-earthed equipment

A person conducting a business or undertaking must ensure that all flammable orcombustible substances that are kept at the workplace (including liquids and gas cylinders)are kept at the lowest practicable quantity.

Where an ignition source is not part of a deliberate workplace activity or process, you mustensure that an ignition source in a hazardous area is eliminated. If this is not reasonablypracticable, the fire risk from the source must be minimised so far as is reasonablypracticable.


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o always return unused liquid to a container labelled for that liquido solvent soaked rags should be stored wet and safely contained after use or

removed from the workshopo store flammable materials including unused liquid in tightly closed containers thatare correctly labelled

o replace lids of containers after each useo do not leave containers of flammable liquid near any heat source or source of

ignition or in direct sunlight, ando place warning signs on storage cabinets and outside storage areas.

To prevent the risk of fire and explosion with electrostatic spray painting, drums of paint and

cleaning solvents should be removed from the exclusion zone before spray painting commences.The cleaning solvent should have a flashpoint of not less than 23 degrees Celsius and preferablyabove the room temperature. Metal solvent containers should only be used when they are earthedand spray guns should not be cleaned with the high voltage supply switched on.

Further guidance on electrostatic spraying is available in AS 2268 Electrostatic paint and powderspray guns for explosive atmospheres and AS 3754-1990 - Safe application of powder coatings byelectrostatic spraying.

7.2 ElectricityElectricity used in spray painting poses unique health risks including:

electrocution from direct or indirect contact with electricity

burns flashes and arcing due to short-circuiting may lead to severe tissue burns or theignition of flammable gases.

Electrical equipment should be kept at a safe distance from spray painting exclusion zones. Thisincludes fans, turntables, drying lamps, fixed lighting and switches, heating equipment, electrical


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Static electricity charges can be generated in any spray painting process if two differently chargedmaterials come into contact. It can be generated by:

touching two metal cans together during decanting clothing or synthetic fibres prone to accumulation of static charge including

nylon, pure wool, wool blends (unless treated) and non-conducting footwear

liquid flowing in pipes or vessels, and

airless spray painting using high fluid pressure (control this by electrically earthing theairless spray gun and any conductive article that is being sprayed including a container thatthe flow from the gun is directed into).

Installation and wiring of electrical equipment in a spray painting workshop, including those in

mixing and storage areas, should comply with AS 2381.1 - Electrical equipment for explosiveatmospheres selection, installation and maintenance general requirements andAS 3000 Electrical installations buildings, structures and premises.

7.3 Confined spaces

Hazards that may be encountered in a confined space include:

chemical agents including combustible gases or vapours, toxic gases or vapours,

combustible or toxic liquids or solids, or potentially explosive dusts

flammable atmospheres, fire or explosion can result from an ignition source such as a

A person conducting a business or undertaking must manage the risks associated with aconfined space including risks of entering, working in, on or near a confined space(including a risk of a person inadvertently entering the confined space).

The WHS Regulations include specific requirements to the control the risks of working in aconfined space.


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performing work at height in a manner that allows workers to form a comfortable position

reducing the amount of force necessary to perform tasks, for example, by using rigging to

lift heavy work pieces and using trolleys to transport work pieces, and ensuring workers do not have to perform manual tasks in excess of their capability.

Further guidance on how to manage the risks of hazardous manual tasks is available in the Codeof Practice: Hazardous Manual Tasks.

7.5 Heat

Exposure to extreme heat is particularly hazardous when working outdoors in direct sunlight, on

hot days and in confined spaces. Wearing personal protective equipment can restrict air movementand sweat evaporation which can prevent the workers body from undergoing natural cooling dueto sweat evaporation.

Working in a hot environment can be hazardous and can cause heat rash, heat stress, heat strokeand result in permanent injury or death. Heat stress can occur gradually and has a range ofsymptoms. While discomfort, dehydration and sweating can be easily noticed by a worker,symptoms including lack of concentration, fatigue, lethargy and confusion are less noticeable.

To prevent workers being exposed to extreme heat you should try to minimise the time that work isundertaken outdoors in direct sunlight on hot days or in hot clothing and use ventilation. Workersshould dress in lightweight clothing, drink cool drinking water and take regular scheduled restbreaks.

7.6 Noise

A person conducting a business or undertaking must manage the risks of hearing loss associatedwith noise at the workplace, including ensuring that the noise a worker is exposed to at the


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using administrative controls, for example limit the amount of time people work in noisyareas

using personal hearing protectors to protect workers from any remaining risk.Further guidance about controlling noise in the workplace is available at Code of Practice:Managing Noise and Preventing Hearing Loss at Work.

7.7 Injection injury

Most injection injuries occur through the use of airless spraying equipment which involves highpressure.

Paint injected into the body may initially appear harmless but may cause a lack of blood supply tothe area, or cause chemical or thermal burns. Solvents and other substances may be injected insufficient quantities to cause symptoms affecting the whole body.

All workers with injection injuries should be referred for immediate medical consultation to minimisethe possibility of gangrene and tissue destruction, which could result in disability throughamputation.


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SPRAY PAINTING AND POWDER COATING SEPTEMBER 2011

DRAFT CODE OF PRACTICE

APPENDIX A SAMPLE RISK ASSESSMENT SHEET

Date: 1 February 2012Assessor: Ann PersonLocation: Main spray painting and baking lineTasks: Paint mixing, colour matching, spraying, baking and cleaning upWorkers involved: P. Stone and J. SaundersDuration of work: Approximately 1.5 hours of preparation and mixing, 5 hours spraying and 1.5 hours cleaning up

HAZARDSIDENTIFIED

Hazardous c hemicals: 2-pack paint containing isocyanates (toxic, possible skin/respiratory sensitisation), thinners containing xylene(harmful by inhalation or through skin, skin irritant).Static electricity: potential contact offlammable solvents with static electricity may result in fire and explosion. Other issues: manualtasks, heat stress, visibility, noise from plant and injection injury.

REVIEW OFHAZARDS

Review control measures, including work processes and systems of work

Review the safety data sheets and label of the products

Review induction training (as required)

Review inspection and maintenance logs of plant

Review notifiable incidents

POSSIBLEEXPOSURE FOREACH TASK

1. Paint mixing

conducted on openbench withgoodnatural ventilation

possible staticelectricity

exposure of skin topaint, and

inhalation of vapour

possible.Determine need for

PPE by use of airmonitoring. Vapoursarising duringdecanting and fromwiping rags.

2. Colour matching

conducted indoors

no ventilation

intermittent inhalationexposure to spraypaint aerosols, and

hands protected butbody unprotected.

3. Spraying

conducted in spraybooth

possible inhalationexposure route

skin exposurepossible to whole ofbody

possibility of skin

injection injuriesheat stress in hot

weather with unbrokenwork, and

noise from extractionsystem and spray gun

4. Baking

vapours from curingpaintand solvents,and

access to drying lineunusual.

5. Clean up

skin exposure extreme togun washing solvents

inhalation of cleaningsolvent and residual paintvapours as conducted inopen

area contaminated bysolvent in cleaning rags

and risk of fire from solvent

soaked rags.


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DRAFT CODE OF PRACTICE PAGE 33 OF 38

EXISTINGCONTROLS

None Latex gloves Half face (class 2respirator). Latexgloves, Spray booth

None Latex gloves

POTENTIAL FOREXPOSURE

Skin- high

Inhalation possiblevapour

Skin high

Inhalation high

Skin high

Inhalation extremelyhigh

Skin high

Paint inhalation -moderate

Skin high

Paint inhalation - moderate

RECOMMENDEDCONTROL Conduct air monitoring

to determineisocyanates and othersolvents to determinelevel of respiratoryprotection required.

Chemically resistantgloves.

Use of static sparkarrester.

Conduct colourmatching in the spraybooth with air suppliedrespirator or conductcolour matching in aspecially constructedextracted booth. Skinprotection by chemically

resistant glovesrequired.

Use of air suppliedrespirator is required.

Full body protection.

Gloves and eyeprotection mandatory.

Boots and bootcovers.

Continued use ofspray booth.

Build extra workbreaks into schedulein hot weather.

Ear protection againstnoise.

If entry is required,wearing of airsupplied respirator ispreferred.

Air monitoring mayestablish the needfor Class 3 organicand gas vapour

filtering respirator.

Skin - hand and armdermal protection required.Chemically resistantgloves.

Inhalation protection fromsolvent vapours using anair supplied respirator,unless air monitoring

indicates that a half-faceair purifying respirator witha solvent vapour cartridgeis adequate.

Alternatively, conduct allequipment cleaning in anautomatic solvent washingsystem.

Store solvent soaked ragssubmerged in water in alidded metal container.

MONITORINGAND HEALTH

SURVEILLANCE

Air monitoring is required during the paint mixing process and also on clean up to determine the need for respiratory protection. Health

monitoring by doctor to be provided for all workers who previously worked with insufficient controls (half-face respirator and latex gloves)and to painters on an ongoing basis due to the high hazard of the isocyanates in paint.


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APPENDIX B SPRAY PAINTING EXCLUSION ZONES AND VENTILATION CONDITIONS

VENTILATION CONDITIONS DISTANCE TIME FACTORS SOURCE COMMENTS

HIGH RISK CHEMICALS

1. Inside closed spray booth thatcomplies with AS/NZS 4114.1 -Spray painting booths,designated spray painting areasand paint mixing rooms - Design,construction and testing

According to AS 4114,distances regardingignition do not applyoutside a closed spraybooth.

At least 5 minutesafter spraying withspray boothoperating.

AS/NZS4114.1

The distance and time factors indicated in this table forhigh chemicals may not be practicable for all conditions.Hazard controls from the risk of explosion and theinhalation of hazardous chemicals will depend on theconditions under which certain types of paints areapplied and should always be selected as part of a riskassessment and control process.

The hazard control factors of distance and time referredto in this appendix are provided as a guide and arebased on AS/NZ 4114.1 Spray Painting Booths and60079-10-1 Classification of Areas Explosive GasAtmosphere- Classification of Hazard zones Explosive Gas Atmospheres.

2. Inside exhaust ventilatedenclosed area (for example, blastunit, closed hangar with exhaustventilation, temporary enclosuresupplied with local exhaustventilation, for example,mucksucker; domestic bathroom

with doors and windows sealedand supplied with local exhaustventilation)

At least 6 metreshorizontal and 3metres vertical.

At least 30 minutesafter spraying withventilation operating.

AS 60079-10-1.


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3. Inside open spray booth thatcomplies with AS/NZS 4114.1

At least 2 metresextending in all

directions from anyopening or outlet.

At least 5 minutesafter spraying with

spray boothoperating.

AS/NZS4114.1

4. Spray painting indoors withoutexhaust ventilation

High hazard paintsshould not be sprayedfor any reason withoutexhaust ventilation,unless other suitablemeans of safelylimiting exposure tothose in the area arein place.

5. Spray painting outdoors Distances should bedetermined byconducting a riskassessment.

Until concentration ofvolatile organicsolvent or othervolatile componentshas dropped belowexposure standard.

AS 60079-10-1.

Air quality can be monitored to ensure concentrationsare not exceeding exposure standards. This may lead tothe exclusion zone distances being adjusted, forexample, greater wind speed, higher temperatures andlow humiditymean that fumes and vapours spread further and alarger exclusion zone may be required.- Risk assessment to determine vertical distance ifrequired.- Administrative and PPE controls should be used fortouch up.


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MEDIUM RISK CHEMICALS

1. Inside closed spray booth According to AS 4114,distances regardingignition do not applyoutside a closed spraybooth.

At least 5 minutesafter spraying withbooth operating.

AS/NZS4114.1

The distance and time factors indicated in this table forHigh hazard may not be practicable for all conditions.Hazard controls from the risk of explosion and theinhalation of hazardous chemicals will depend on theconditions under which certain types of paints areapplied and should always be selected as part of a riskassessment and control process.

The hazard control factors of distance and time referredto in this appendix are provided as a guide and arebased on AS/NZ 4114.1 and 60079-10-1

2. Inside exhaust ventilated

enclosedarea

At least 6 metres

extending in alldirections from anyopening or outlet.

At least 30 minutes

after spraying withventilation operating.

AS 60079-

10-1.

3. Inside open spray booth At least 2 metresextending in alldirections from anyopening or outlet.


AS/NZS4114.1

4. Indoors without exhaustventilation

Distances should bedetermined byconducting a riskassessment.

Until concentration ofvolatile organicsolvent or othervolatile componentshas dropped belowexposure standard.

AS 60079-10-1.

Should be avoided unless air monitoring can be used toconfirm that all bystanders are not being exposed tovapours exceeding the exposure standards.


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5. Spray painting outdoors Distances should bedetermined by

conducting a riskassessment.

Until concentration ofvolatile organic

solvent or othervolatile componentshas dropped belowexposure standard.

AS 60079-10-1.

Air quality can be monitored to determine concentrationsare not exceeding exposure standards. This may lead to

the exclusion zone distances being adjusted, forexample, greater wind speed, higher temperatures andlow humidity mean that fumes and vapours spreadfurther and a larger exclusion zone may be required.Risk assessment to determine vertical distance ifrequired.- Administrative and PPE controls should be used fortouch up.

LOW RISK CHEMICALS

1. Inside open spray booth that

complies with AS/NZS 4114.1

At least 5 minutes

after spraying withboothoperating.

AS 4114.1 The distance and time factors indicated in this table for

high hazard, chemicals may not be practicable for allconditions. Hazard controls from the risk of explosionand the inhalation of hazardous chemicals will dependon the conditions under which certain types of paints areapplied and should always be selected as part of a riskassessment and control process.

The hazard control factors of distance and time referredto in this appendix are provided as a guide and arebased on AS/NZ 4114.1 and 60079-10-1

2. Inside exhaust ventilatedenclosed area

At least 6 metresextending in alldirections from any

opening or outlet.

AS 60079-10-1

3. Inside open spray booth At least 2 metresextending in alldirections from anyopening or outlet.


AS 4114.1


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4. Indoors without exhaustventilation

Until concentration ofvolatile components

has dropped belowexposure standard.

AS 60079-10-1.

5. Outdoors At least 3 metres in alldirections.

No time restriction forre-entry.

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